Abstract: The end of the line controls of the finished products in
the automotive industry is important. The control that has been
conducted with the manual methods for the sliding doors tracks is not
sufficient and faulty products cannot be identified. As a result, the
customer has the faulty products. In the scope of this study, the
design criteria of the PLC integrated modular end of line control unit
has been examined, designed and manufactured to make the control
of the 10 different track profile to 2 different vehicles with an
objective to minimize the salvage costs by obtaining more sensitive,
certain and accurate measurement results. In the study that started
with literature and patent review, the design inputs have been
specified, the technical concept has been developed, computer
supported mechanic design, control system and automation design,
design review and design improvement have been made. Laser
analog sensors at high sensitivity, probes and modular blocks have
been used in the unit. The measurement has been conducted in the
system and it is observed that measurement results are more sensitive
than the previous methods that we use.
Abstract: A sliding door system is used in commercial vehicles
and passenger cars to allow a larger unobstructed access to the
interior for loading and unloading. The movement of a sliding door
on vehicle body is ensured by mechanisms and tracks having special
cross-section which is manufactured by roll forming and stretch
bending process. There are three tracks and three mechanisms which
are called upper, central and lower on a sliding door system. There
are static requirements as strength on different directions, rigidity for
mechanisms, door drop off, door sag; dynamic requirements as high
energy slam opening-closing and durability requirement to validate
these products. In addition, there is a kinematic requirement to find
out force values from door handle during manual operating. In this
study, finite element analysis and physical test results which are
realized for sliding door systems will be shared comparatively.
Abstract: In Automotive Industry, sliding door systems that are
also used as body closures are safety members. Extreme product tests
are realized to prevent failures in design process, but these tests
realized experimentally result in high costs. Finite element analysis is
an effective tool used for design process. These analyses are used
before production of prototype for validation of design according to
customer requirement. In result of this, substantial amount of time
and cost is saved. Finite element model is created for geometries that are designed in
3D CAD programs. Different element types as bar, shell and solid,
can be used for creating mesh model. Cheaper model can be created
by selection of element type, but combination of element type that
was used in model, number and geometry of element and degrees of
freedom affects the analysis result. Sliding door system is a good
example which used these methods for this study. Structural analysis
was realized for sliding door mechanism by using FE models. As
well, physical tests that have same boundary conditions with FE
models were realized. Comparison study for these element types,
were done regarding test and analyses results then optimum
combination was achieved.
Abstract: High frequency automotive interior noise above 500
Hz considerably affects automotive passenger comfort. To reduce this
noise, sound insulation material is often laminated on body panels or
interior trim panels. For a more effective noise reduction, the sound
reduction properties of this laminated structure need to be estimated.
We have developed a new calculate tool that can roughly calculate the
sound absorption and insulation properties of laminate structure and
handy for designers. In this report, the outline of this tool and an
analysis example applied to floor mat are introduced.
Abstract: Polyaniline is an indispensible component in lightemitting
devices (LEDs), televisions, cellular telephones, automotive,
corrosion-resistant coatings, actuators etc. The electrical conductivity
properties was found be increased by introduction of metal nano
particles. In the present study, an attempt has been made to utilize
platinum nano particles to achieve the improved electrical properties.
Polyaniline and Pt-polyaniline composite are synthesized by
electrochemical routes. X-ray diffractometer confirms the amorphous
nature of polyaniline. The Bragg’s diffraction peaks correspond to
platinum nanoparticles in Pt-polyaniline composite and
thermogravimetric analyzer indicates its decomposition at certain
temperature. The Scanning Electron Micrographs of colloidal
platinum nanoparticles were spherical, uniform shape in the
composite. The current-voltage (I-V) characteristics of the PANI and
composites were also studied which indicate a significant decreasing
resistivity than PANI-Platinum after introduction of pt nanoparticles
in the matrix of polyaniline (PANI).
Abstract: The MEMS pressure sensor has been introduced and
presented in this paper. The types of pressure sensor and its theory of
operation are also included. The latest MEMS technology, the
fabrication processes of pressure sensor are explored and discussed.
Besides, various device applications of pressure sensor such as tire
pressure-monitoring system, diesel particulate filter and others are
explained. Due to further miniaturization of the device nowadays, the
pressure sensor with nanotechnology (NEMS) is also reviewed. The
NEMS pressure sensor is expected to have better performance as well
as lower in its cost. It has gained an excellent popularity in many
applications.
Abstract: In present global scenario, aluminum alloys are
coining the attention of many innovators as competing structural
materials for automotive and space applications. Comparing to other
challenging alloys, especially, 7xxx series aluminum alloys have
been studied seriously because of benefits such as moderate strength;
better deforming characteristics and affordable cost. It is expected
that substitution of aluminum alloys for steels will result in great
improvements in energy economy, durability and recyclability.
However, it is necessary to improve the strength and the formability
levels at low temperatures in aluminum alloys for still better
applications. Aluminum–Zinc–Magnesium with or without other
wetting agent denoted as 7XXX series alloys are medium strength
heat treatable alloys. In addition to Zn, Mg as major alloying
additions, Cu, Mn and Si are the other solute elements which
contribute for the improvement in mechanical properties by suitable
heat treatment process. Subjecting to suitable treatments like age
hardening or cold deformation assisted heat treatments; known as low
temperature thermomechanical treatments (LTMT) the challenging
properties might be incorporated. T6 is the age hardening or
precipitation hardening process with artificial aging cycle whereas T8
comprises of LTMT treatment aged artificially with X% cold
deformation. When the cold deformation is provided after solution
treatment, there is increase in hardness related properties such as
wear resistance, yield and ultimate strength, toughness with the
expense of ductility. During precipitation hardening both hardness
and strength of the samples are increasing. The hardness value may
further improve when room temperature deformation is positively
supported with age hardening known as thermomechanical treatment.
It is intended to perform heat treatment and evaluate hardness, tensile
strength, wear resistance and distribution pattern of reinforcement in
the matrix. 2 to 2.5 and 3 to 3.5 times increase in hardness is reported
in age hardening and LTMT treatments respectively as compared to
as-cast composite. There was better distribution of reinforcements in
the matrix, nearly two fold increase in strength levels and up to 5
times increase in wear resistance are also observed in the present
study.
Abstract: Elastomeric polymer foam has been used widely in
the automotive industry, especially for isolating unwanted vibrations.
Such material is able to absorb unwanted vibration due to its
combination of elastic and viscous properties. However, the ‘creep
effect’, poor stress distribution and susceptibility to high
temperatures are the main disadvantages of such a system.
In this study, improvements in the performance of elastomeric
foam as a vibration isolator were investigated using the concept of
Foam Filled Fluid (FFFluid). In FFFluid devices, the foam takes the
form of capsule shapes, and is mixed with viscous fluid, while the
mixture is contained in a closed vessel. When the FFFluid isolator is
affected by vibrations, energy is absorbed, due to the elastic strain of
the foam. As the foam is compressed, there is also movement of the
fluid, which contributes to further energy absorption as the fluid
shears. Also, and dependent on the design adopted, the packaging
could also attenuate vibration through energy absorption via friction
and/or elastic strain.
The present study focuses on the advantages of the FFFluid
concept over the dry polymeric foam in the role of vibration isolation.
This comparative study between the performance of dry foam and the
FFFluid was made according to experimental procedures. The paper
concludes by evaluating the performance of the FFFluid isolator in
the suspension system of a light vehicle. One outcome of this
research is that the FFFluid may preferable over elastomer isolators
in certain applications, as it enables a reduction in the effects of high
temperatures and of ‘creep effects’, thereby increasing the reliability
and load distribution. The stiffness coefficient of the system has
increased about 60% by using an FFFluid sample. The technology
represented by the FFFluid is therefore considered by this research
suitable for application in the suspension system of a light vehicle.
Abstract: Interstitial free steels possess better formability and
have many applications in automotive industries. Forming limit
diagrams (FLDs) indicate the formability of materials which can be
determined by experimental and finite element (FE) simulations.
FLDs were determined experimentally by LDH test, utilizing optical
strain measurement system for measuring the strains in different
width specimens and by FE simulations in Interstitial Free (IF) and
Interstitial Free High Strength (IFHS) steels. In this study, the
experimental and FE simulated FLDs are compared and also the
stress based FLDs were investigated.
Abstract: Due to today’s globalization as well as outsourcing
practices of the companies, the Supply Chain (SC) performances
have become more dependent on the efficient movement of material
among places that are geographically dispersed, where there is more
chance for disruptions. One such disruption is the quality and
delivery uncertainties of outsourcing. These uncertainties could lead
the products to be unsafe and, as is the case in a number of recent
examples, companies may have to end up in recalling their products.
As a result of these problems, there is a need to develop a
methodology for selecting suppliers globally in view of risks
associated with low quality and late delivery. Accordingly, we
developed a two-stage stochastic model that captures the risks
associated with uncertainty in quality and delivery as well as a
solution procedure for the model. The stochastic model developed
simultaneously optimizes supplier selection and purchase quantities
under price discounts over a time horizon. In particular, our target is
the study of global organizations with multiple sites and multiple
overseas suppliers, where the pricing is offered in suppliers’ local
currencies. Our proposed methodology is applied to a case study for a
US automotive company having two assembly plants and four
potential global suppliers to illustrate how the proposed model works
in practice.
Abstract: In this paper we propose a computer-aided solution
with Genetic Algorithms in order to reduce the drafting of reports:
FMEA analysis and Control Plan required in the manufacture of the
product launch and improved knowledge development teams for
future projects. The solution allows to the design team to introduce
data entry required to FMEA. The actual analysis is performed using
Genetic Algorithms to find optimum between RPN risk factor and
cost of production. A feature of Genetic Algorithms is that they are
used as a means of finding solutions for multi criteria optimization
problems. In our case, along with three specific FMEA risk factors is
considered and reduce production cost. Analysis tool will generate
final reports for all FMEA processes. The data obtained in FMEA
reports are automatically integrated with other entered parameters in
Control Plan. Implementation of the solution is in the form of an
application running in an intranet on two servers: one containing
analysis and plan generation engine and the other containing the
database where the initial parameters and results are stored. The
results can then be used as starting solutions in the synthesis of other
projects. The solution was applied to welding processes, laser cutting
and bending to manufacture chassis for buses. Advantages of the
solution are efficient elaboration of documents in the current project
by automatically generating reports FMEA and Control Plan using
multiple criteria optimization of production and build a solid
knowledge base for future projects. The solution which we propose is
a cheap alternative to other solutions on the market using Open
Source tools in implementation.
Abstract: The popularity of quality management system models
continues to grow despite the transitional crisis in 2008. Their
development is associated with demands of the new requirements for
entrepreneurs, such as risk analysis projects and more emphasis on
supervision of outsourced processes. In parallel, it is appropriate to
focus attention on the selection of companies aspiring to a quality
management system. This is particularly important in the automotive
supplier industry, where requirements transferred to the levels in the
supply chain should be clear, transparent and fairly satisfied. The
author has carried out a series of researches aimed at finding the
factors that allow for the effective implementation of the quality
management system in automotive companies. The research was
focused on four groups of companies: 1) manufacturing (parts and
assemblies for the purpose of sale or for vehicle manufacturers), 2)
service (repair and maintenance of the car) 3) services for the
transport of goods or people, 4) commercial (auto parts and vehicles).
The identified determinants were divided into two types of criteria:
internal and external, as well as hard and soft. The article presents the
hard – technical factors that an automotive company must meet in
order to achieve the goal of the quality management system
implementation.
Abstract: As the trend in automotive technology is fast moving
towards hybridization and electrification to curb emissions as well as
to improve the fuel efficiency, air-conditioning systems in passenger
cars have not caught up with this trend and still remain as the major
energy consumers amongst others. Adsorption based air-conditioning
systems, e.g. with silica-gel water pair, which are already in use for
residential and commercial applications, are now being considered as
a technology leap once proven feasible for the passenger cars. In this
paper we discuss a methodology, challenges and feasibility of
implementing an adsorption based air-conditioning system in a
passenger car utilizing the exhaust waste heat. We also propose an
optimized control strategy with interfaces to the engine control unit
of the vehicle for operating this system with reasonable efficiency
supported by our simulation and validation results in a prototype
vehicle, additionally comparing to existing implementations,
simulation based as well as experimental. Finally we discuss the
influence of start-stop and hybrid systems on the operation strategy of
the adsorption air-conditioning system.
Abstract: The secondary alloy A226 is used for many
automotive casting produced by mould casting and high pressure die
casting. This alloy has excellent castability, good mechanical
properties and cost-effectiveness. Production of primary aluminium
alloys belong to heavy source fouling of life environs. The European
Union calls for the emission reduction and reduction in energy
consumption therefore increase production of recycled (secondary)
aluminium cast alloys. The contribution is deal with influence of
recycling on the quality of the casting made from A226 in automotive
industry. The properties of the casting made from secondary
aluminium alloys were compared with the required properties of
primary aluminium alloys. The effect of recycling on microstructure
was observed using combination different analytical techniques (light
microscopy upon black-white etching, scanning electron microscopy
- SEM upon deep etching and energy dispersive X-ray analysis -
EDX). These techniques were used for the identification of the
various structure parameters, which was used to compare secondary
alloy microstructure with primary alloy microstructure.
Abstract: Press-hardened profiles are used e.g. for automotive
applications in order to improve light weight construction due to the
high reachable strength. The application of interior water-air spray
cooling contributes to significantly reducing the cycle time in the
production of heat-treated tubes. This paper describes a new
manufacturing method for producing press-hardened hollow profiles
by means of an additional interior cooling based on a water-air spray.
Furthermore, this paper provides the results of thorough
investigations on the properties of press-hardened tubes in
dependence of varying spray parameters.
Abstract: In more complex systems, such as automotive
gearbox, a rigorous treatment of the data is necessary because there
are several moving parts (gears, bearings, shafts, etc.), and in this
way, there are several possible sources of errors and also noise. The
basic objective of this work is the detection of damage in automotive
gearbox. The detection methods used are the wavelet method, the
bispectrum; advanced filtering techniques (selective filtering) of
vibrational signals and mathematical morphology. Gearbox vibration
tests were performed (gearboxes in good condition and with defects)
of a production line of a large vehicle assembler. The vibration
signals are obtained using five accelerometers in different positions
of the sample. The results obtained using the kurtosis, bispectrum,
wavelet and mathematical morphology showed that it is possible to
identify the existence of defects in automotive gearboxes.
Abstract: The structures obtained with the use of sandwich
technologies combine low weight with high energy absorbing
capacity and load carrying capacity. Hence, there is a growing and
markedly interest in the use of sandwiches with aluminum foam core
because of very good properties such as flexural rigidity and energy
absorption capability. In the current investigation, the static threepoint
bending tests were carried out on the sandwiches with
aluminum foam core and glass fiber reinforced polymer (GFRP)
skins at different values of support span distances aiming the analyses
of their flexural performance. The influence of the core thickness and
the GFRP skin type was reported in terms of peak load and energy
absorption capacity. For this purpose, the skins with two different
types of fabrics which have same thickness value and the aluminum
foam core with two different thicknesses were bonded with a
commercial polyurethane based flexible adhesive in order to combine
the composite sandwich panels. The main results of the bending tests
are: force-displacement curves, peak force values, absorbed energy,
collapse mechanisms and the effect of the support span length and
core thickness. The results of the experimental study showed that the
sandwich with the skins made of S-Glass Woven fabrics and with the
thicker foam core presented higher mechanical values such as load
carrying and energy absorption capacities. The increment of the
support span distance generated the decrease of the mechanical
values for each type of panels, as expected, because of the inverse
proportion between the force and span length. The most common
failure types of the sandwiches are debonding of the lower skin and
the core shear. The obtained results have particular importance for
applications that require lightweight structures with a high capacity
of energy dissipation, such as the transport industry (automotive,
aerospace, shipbuilding and marine industry), where the problems of
collision and crash have increased in the last years.
Abstract: Ti6Al4V alloy is highly used in the automotive and
aerospace industry due to its good machining characteristics. Micro
EDM drilling is commonly used to drill micro hole on extremely hard
material with very high depth to diameter ratio. In this study, the
parameters of micro-electrical discharge machining (EDM) in drilling
of Ti6Al4V alloy is optimized for higher machining accuracy with
less hole-dilation and hole taper ratio. The micro-EDM machining
parameters includes, peak current and pulse on time. Fuzzy analysis
was developed to evaluate the machining accuracy. The analysis
shows that hole-dilation and hole-taper ratio are increased with the
increasing of peak current and pulse on time. However, the surface
quality deteriorates as the peak current and pulse on time increase.
The combination that gives the optimum result for hole dilation is
medium peak current and short pulse on time. Meanwhile, the
optimum result for hole taper ratio is low peak current and short pulse
on time.
Abstract: Micro-alloyed steel components are used in
automotive industry for the necessity to make the manufacturing
process cycles shorter when compared to conventional steel by
eliminating heat treatment cycles, so an important saving of costs and
energy can be reached by reducing the number of operations. Microalloying
elements like vanadium, niobium or titanium have been
added to medium carbon steels to achieve grain refinement with or
without precipitation strengthening along with uniform
microstructure throughout the matrix. Present study reports the
applicability of medium carbon vanadium micro-alloyed steel in hot
forging. Forgeability has been determined with respect to different
cooling rates, after forging in a hydraulic press at 50% diameter
reduction in temperature range of 900-11000C. Final microstructures,
hardness, tensile strength, and impact strength have been evaluated.
The friction coefficients of different lubricating conditions, viz.,
graphite in hydraulic oil, graphite in furnace oil, DF 150 (Graphite,
Water-Based) die lubricant and dry or without any lubrication were
obtained from the ring compression test for the above micro-alloyed
steel. Results of ring compression tests indicate that graphite in
hydraulic oil lubricant is preferred for free forging and dry lubricant
is preferred for die forging operation. Exceptionally good forgeability
and high resistance to fracture, especially for faster cooling rate has
been observed for fine equiaxed ferrite-pearlite grains, some amount
of bainite and fine precipitates of vanadium carbides and
carbonitrides. The results indicated that the cooling rate has a
remarkable effect on the microstructure and mechanical properties at
room temperature.
Abstract: Managing and improving efficiency in the current
highly competitive global automotive industry demands that those
companies adopt leaner and more flexible systems. During the past
20 years the domestic automotive industry in North America has been
focusing on establishing new management strategies in order to meet
market demands. The lean management process also known as
Toyota Manufacturing Process (TPS) or lean manufacturing
encompasses tools and techniques that were established in order to
provide the best quality product with the fastest lead time at the
lowest cost. The following paper presents a study that focused on
improving labor efficiency at one of the Big Three (Ford, GM,
Chrysler LLC) domestic automotive facility in North America. The
objective of the study was to utilize several lean management tools in
order to optimize the efficiency and utilization levels at the “Pre-
Marriage” chassis area in a truck manufacturing and assembly
facility. Utilizing three different lean tools (i.e. Standardization of
work, 7 Wastes, and 5S) this research was able to improve efficiency
by 51%, utilization by 246%, and reduce operations by 14%. The
return on investment calculated based on the improvements made
was 284%.